U.S. patent application number 12/664103 was filed with the patent office on 2010-08-26 for method and system for state encoding.
This patent application is currently assigned to SHELL OIL COMPANY. Invention is credited to James Po Kong.
Application Number | 20100214069 12/664103 |
Document ID | / |
Family ID | 40156658 |
Filed Date | 2010-08-26 |
United States Patent
Application |
20100214069 |
Kind Code |
A1 |
Kong; James Po |
August 26, 2010 |
METHOD AND SYSTEM FOR STATE ENCODING
Abstract
A system comprising at least one piece of equipment; a plurality
of sensors adapted to measure one or more operating parameters of
the equipment; and a signature generator adapted to encode a
plurality of data streams from the sensors into an operating
signature for the equipment.
Inventors: |
Kong; James Po; (Katy,
TX) |
Correspondence
Address: |
SHELL OIL COMPANY
P O BOX 2463
HOUSTON
TX
772522463
US
|
Assignee: |
SHELL OIL COMPANY
Houston
TX
|
Family ID: |
40156658 |
Appl. No.: |
12/664103 |
Filed: |
June 16, 2008 |
PCT Filed: |
June 16, 2008 |
PCT NO: |
PCT/US08/67116 |
371 Date: |
May 4, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60944286 |
Jun 15, 2007 |
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Current U.S.
Class: |
340/10.1 |
Current CPC
Class: |
G06K 7/10009 20130101;
G05B 23/0229 20130101 |
Class at
Publication: |
340/10.1 |
International
Class: |
H04Q 5/22 20060101
H04Q005/22 |
Claims
1. A system comprising: at least one piece of equipment; a
plurality of sensors adapted to measure one or more operating
parameters of the equipment; and a signature generator adapted to
encode a plurality of data streams from the sensors into an
operating signature for the equipment.
2. The system of claim 1, further comprising: a signature
repository containing a number of signatures that correspond to
known operating conditions of the equipment.
3. The system of claim 2, further comprising: an action repository
containing a number of actions to be taken which correspond to the
signatures in the signature repository.
4. The system of claim 2, further comprising: a signature analyzer
adapted to compare a signature from the signature generator with a
known signature from the signature repository.
5. The system of claim 2, further comprising: an event engine
adapted to take a predetermined action when a signature from the
signature generator matches a known signature from the signature
repository.
6. The system of claim 1, wherein: the signature generator produces
a signature comprising at least two of a high, normal, and low
range bit string.
7. The system of claim 6, wherein: the signature generator converts
the bit string to a number.
8. A method comprising: identifying at least one piece of equipment
to be monitored; installing a plurality of sensors to measure
operating data of the equipment; establishing an operating range
for each of the sensors; and creating an encoding key for each of
the ranges.
9. The method of claim 8, further comprising: converting a
plurality of the encoding keys into an operating signature.
10. The method of claim 8, further comprising: storing a plurality
of known signatures in a database, the signatures corresponding to
known operating conditions of the equipment.
11. The method of claim 10, further comprising: storing a plurality
of actions to take in a database, the actions corresponding to the
known signatures.
12. The method of claim 9, further comprising: comparing the
operating signature with known signatures in the database.
13. The method of claim 12, further comprising: taking a
predetermined action when the operating signature matches a known
signatures in the database.
14. The method of claim 9, further comprising: storing a new
signature in a database, the signature corresponding to an observed
or measured operating condition of the equipment.
15. The method of claim 14, further comprising: storing a new
action in a database, the action corresponding to a new signature,
the new action designed to correct observed or measured operating
conditions of the equipment.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority, pursuant to 35 U.S.C.
.sctn.119(e), of U.S. Provisional Application Ser. No. 60/944,286
entitled "REMOTE MONITORING SYSTEMS AND METHODS," filed on Jun. 15,
2007 in the name of James Kong and is hereby incorporated by
reference.
BACKGROUND
[0002] U.S. Patent Application Publication 2008/0129507 discloses a
method for employing radio frequency (RF) identifier (ID)
transponder tags (RFID tags) to create a unique identifier, termed
an RFID signature, for use within a data processing system with
respect to a person or an object. An interrogation signal is
transmitted toward a person or an object with which a set of one or
more RFID tags are physically associated. A first set of RFID tag
identifiers are obtained from an interrogation response signal or
signals returned from the set of one or more RFID tags. A
mathematical operation is performed on the first set of RFID tag
identifiers to generate an RFID signature value, which is employed
as an identifier for the person or the object within the data
processing system with respect to a transaction that is performed
by the data processing system on behalf of the person or the
object. U.S. Patent Application Publication 2008/0129507 is herein
incorporated by reference in its entirety.
[0003] U.S. Patent Application Publication 2008/0016353 discloses a
method and system for verifying the authenticity and integrity of
files transmitted through a computer network. Authentication
information is encoded in the filename of the file. In a preferred
embodiment, authentication information is provided by computing a
hash value of the file, computing a digital signature of the hash
value using a private key, and encoding the digital signature in
the filename of the file at a predetermined position or using
delimiters, to create a signed filename. Upon reception of a file,
the encoded digital signature is extracted from the signed
filename. Then, the encoded hash value of the file is recovered
using a public key and extracted digital signature, and compared
with the hash value computed on the file. If the decoded and
computed hash values are identical, the received file is processed
as authentic. U.S. Patent Application Publication 2008/0016353 is
herein incorporated by reference in its entirety.
SUMMARY
[0004] One aspect of the invention provides a system comprising at
least one piece of equipment; a plurality of sensors adapted to
measure one or more operating parameters of the equipment; and a
signature generator adapted to encode a plurality of data streams
from the sensors into an operating signature for the equipment.
[0005] Another aspect of the invention provides a method comprising
identifying at least one piece of equipment to be monitored;
installing a plurality of sensors to measure operating data of the
equipment; establishing an operating range for each of the sensors;
and creating an encoding key for each of the ranges.
[0006] Other aspects of the invention will be apparent from the
following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 shows a schematic diagram of a system in accordance
with one or more embodiments of the invention.
[0008] FIG. 2 shows an example schematic diagram of a signature in
accordance with one or more embodiments of the invention.
[0009] FIG. 3 show patterns in accordance with one or more
embodiments of the invention.
[0010] FIGS. 4-7 show flowcharts in accordance with one or more
embodiments of the invention.
[0011] FIGS. 8A-8B show an example in accordance with one or more
embodiments of the invention.
[0012] FIG. 9 shows a computer system in accordance with one or
more embodiments of the invention.
DETAILED DESCRIPTION
[0013] Specific embodiments of the invention will now be described
in detail with reference to the accompanying figures. Like elements
in the various figures are denoted by like reference numerals for
consistency.
[0014] In the following detailed description of embodiments of the
invention, numerous specific details are set forth in order to
provide a more thorough understanding of the invention. However, it
will be apparent to one of ordinary skill in the art that the
invention may be practiced without these specific details. In other
instances, well-known features have not been described in detail to
avoid unnecessarily complicating the description.
[0015] In general, embodiments of the invention provide a method
and system for analyzing equipment using encoded data obtained from
the equipment. The data represents the operational conditions of
the equipment. The operational conditions may define both
conditions internal to the equipment, such as how well the
equipment is operating, as well as conditions external to the
equipment, such as the environment in which the equipment is
operating. State detectors monitoring the equipment are used to
obtain unprocessed state detector data values representing the
operational conditions. Unprocessed state detector data values from
different state detectors may be processed, such as by being
mathematically combined, to create processed state detector data
values. The different state detector data values, including
processed and/or unprocessed state detector data values, are
encoded. The encoding is based on whether the value is in a
predefined range of values. The ranges are defined based on
acceptable limits for the equipment. For example, the range may
include a high range, an above normal range, a normal range, a
below normal range, and a low range. If value is within the range,
then one or more bits are set to indicate that the value is within
the range. The bits are concatenated to generate a signature. Thus,
the single signature represents the state of the equipment at a
moment in time. Specifically, a single signature concisely
represents which processed and/or unprocessed state detector data
values are within acceptable limits and which state detector data
values are outside of acceptable limits.
[0016] One or more signatures may be compared with stored patterns
of signatures. A pattern associates the occurrence of one or more
classified or known signatures with a definition of how the
equipment is functioning. Specifically, when one or more generated
signatures matches the classified signatures in a pattern, then the
equipment is determined to be functioning as defined by the
pattern. Thus, by comparing one or more generated signatures with
known patterns of signatures, embodiments of the invention may be
used to evaluate the state of the equipment.
FIG. 1:
[0017] FIG. 1 shows a schematic diagram of a system in accordance
with one or more embodiments of the invention. In one or more
embodiments of the invention, the system includes equipment (100),
a data repository (102), a signature generator (104), and a
signature analyzer (106). Each of these components is described
below.
[0018] Equipment (100) corresponds to the physical devices that are
being monitored. For example, the equipment (100) may include
gearboxes, compressors, pumps, lubricating systems, as well as
other such equipment. In one or more embodiments of the invention,
the equipment includes functionality to perform oilfield
operations. In one or more embodiments of the invention, each piece
of equipment is represented by separate signatures. Further, one
piece of equipment may be a component of another piece of
equipment. For example, one piece of equipment may correspond to a
compressor while another piece of equipment corresponds to a
bearing in the compressor. In such a scenario, one series of
signatures (i.e., signatures generated from state detector data
obtained at different moments in time) may represent the compressor
with the bearing while another series of signatures represents only
the bearing.
[0019] In one or more embodiments of the invention, the equipment
(100) is monitored by state detectors (112). Each state detector
(112) includes functionality to obtain unprocessed state detector
data. The state detector (112) may be a sensor, a person monitoring
the equipment, or any other monitoring unit that obtains data about
the operations conditions. For example, state detector M (112M) may
be a temperature sensor while state detector N (112N) detects the
composition of fluid from the oilfield.
[0020] The state detector data represents operational conditions of
the equipment. An operational condition includes internal or
external conditions under which the equipment is operating. For
example, the operational condition may include temperature,
pressure, composition, health of the equipment, performance of the
equipment, and other such data. The state detector data may include
unprocessed state detector data and/or processed state detector
data. Unprocessed state detector data corresponds to data obtained
directly from the equipment, such as temperature, pressure, flow,
density, viscosity. Processed state detector data corresponds to
data calculated from the unprocessed state detector data, such as
changes in temperature, the difference between inlet and outlet
pressure, efficiency, and other such calculated data. Thus,
processed state detector data may represent the combination of
state detector data values from different pieces of equipment. In
one or more embodiments of the invention, each state detector data
value in the combination is collected at the same moment in time or
within a defined period of time.
[0021] In one or more embodiments of the invention, the data
repository (102) is any type of storage unit and/or device (e.g., a
file system, database, collection of tables, or any other storage
mechanism) for storing data. Further, the data repository (102) may
include multiple different storage units and/or devices. The
multiple different storage units and/or devices may or may not be
of the same type or located at the same physical site. For example,
a portion of the data repository (102) may be on an internal server
while another portion is distributed across the Internet. In one or
more embodiments of the invention, the data repository (102), or a
portion thereof, is secure. In one or more embodiments of the
invention, the data repository (102) includes detector information
(108) and a pattern repository (110). The detector information
(108) and the pattern repository (110) are discussed below.
[0022] Detector information (108) includes an encode key set (114)
for units of processed and unprocessed state detector data. For
example, an encode key set S (114S) may correspond to state
detector M (112M) while encode key set T (114T) corresponds to
processed state detector data defining the performance of the
equipment (100). An encode key set (114) includes one or more
encode keys. Each encode key defines a mapping between the possible
values of the state detector data and a bit value in the signature.
Specifically, the encode key assigns a range of possible values or
a discrete group of possible values of the state detector data to a
value of a bit in the signature. The encode keys are discussed in
further detail below.
[0023] Continuing with FIG. 1, a signature generator (104) includes
functionality to generate a signature using the detector
information (108). As discussed above, a signature represents the
state of the equipment at a moment in time. Specifically, the
signature includes the encoded processed and unprocessed state
detector data values obtained from the state detectors (112). The
signature is discussed below and in FIG. 2.
[0024] Continuing with FIG. 1, the data repository (102) may also
include a pattern repository (110). A pattern repository (110) is a
storage unit for patterns (116) of classified signatures. A pattern
associates the occurrence of one or more classified signatures with
a definition of how the equipment is functioning. A classified
signature is any signature in a defined pattern. The patterns may
be used to evaluate the signature. When generated signatures match
a pattern, the equipment is determined to be performing as defined
by the pattern. The patterns (116) may be used to detect failure or
a potential for failure in the equipment, the type of failure, the
general condition of the equipment, how well the equipment is
processing, as well as other uses. Patterns are discussed below and
in FIGS. 3A-3C.
[0025] Continuing with FIG. 1, each pattern (116) in the pattern
repository (110) may have a corresponding action (118). The action
(118) defines the steps to perform when the pattern is detected.
For example, the action (118) may define parts of the equipment to
replace, adjustments to make to the equipment, as well as other
actions to perform. Further, the action (118) may define a degree
of urgency to perform the steps of the action and consequence of
delaying or not performing the action.
[0026] In addition to the detector information (108) and the
pattern repository (110), the data repository (102) may also
include a repository (not shown) for state detector data. For
example, the processed and unprocessed state detector data may be
stored in the repository. In one or more embodiments of the
invention, generated signatures are stored in the repository. The
repository of state detector data may be used, for example, to
create or modify encode key sets and patterns in the data
repository (102). For example, the repository of state detector
data may be used to create a pattern for detecting a newly
discovered type of failure of the equipment.
[0027] Continuing with FIG. 1, the signature analyzer (106)
includes functionality to evaluate the equipment by analyzing the
generated signatures. The signature analyzer (106) includes a match
finder (120), identified matches (122), and an event engine (124).
The match finder (120), identified matches (122), and the event
engine (124) are discussed below.
[0028] The match finder (120) includes functionality to identify
when one or more generated signatures match the patterns in the
pattern repository (110). Specifically, the match finder (120)
includes functionality to determine whether a signature generated
by the signature generator (104) matches a classified signature in
a pattern (116). Further, the match finder (120) includes
functionality to determine whether an entire pattern is matched by
one or more generated signatures.
[0029] Identified match repository (122) is a storage repository
for generated signatures that match classified signatures in a
pattern. Specifically, the identified match repository (122) may
store signatures while the match finder (120) determines whether
the generated signatures match a pattern (116). In one or more
embodiments of the invention, the identified matches are stored
with the patterns that may be potentially matched. For example,
consider the scenario in which a pattern requires that seven
specific signatures are generated within a specific duration. The
first six signatures that match six classified signatures in the
example pattern are stored in the identified match repository (122)
with identification of the example pattern. When the seventh
generated signature is analyzed, the match finder may access the
identified match repository (122) to determine whether the six
previously generated signatures with the seventh generated
signature match the example pattern in the required duration.
[0030] In one or more embodiments of the invention, the event
engine (124) includes functionality to perform the action (118)
and/or generate an alert when the pattern is matched. Specifically,
the event engine (124) may include functionality to control the
equipment to perform the action (118). Alternatively, or
additionally, the event engine (124) may include functionality to
generate an alert, such as create an auditory alarm, send an email
or text message to an operator, display a warning message, or
perform any other steps defined by the action.
FIG. 2:
[0031] FIG. 2 shows an example signature (130) in accordance with
one or more embodiments of the invention. The following is for
exemplary purposes only and not intended to limit the scope of the
invention. In one or more embodiments of the invention, the data
type of the signature (130) is an unsigned Big Int. A Big Int has
sixty-four bits that are stored as a single block of data. An
unsigned Big Int represents integer values of 0 to 2.sup.64-1. In
one or more embodiments of the invention, the signature (130) is a
concatenation of four Big Ints. Those skilled in the art will
appreciate that different sizes of the signature and different data
types may be used without departing from the scope of the
invention.
[0032] In FIG. 2, the signature (130) includes bit strings for
encoding a high range, a normal range, and a low range.
Specifically, when a state detector data value is in the high
range, a bit may be set to "1" in the high range bit string (132)
with the corresponding bit set to "0" in the low range bit string.
When the state detector data value is in the low range, a bit may
be set to "1" in the low range bit string (134) with the
corresponding bit set to "0" in the high range bit string. A state
detector data value that is in the normal range has the bit set to
"0" in the high range bit string (132) and "0" in the low range bit
string (134).
[0033] As discussed above, the encoding of state detector data
values is performed by an encode key that maps the value to bits in
the bit string. Each encode key in the encode key set has a
corresponding position for a bit (136, 138) in the signature (130)
in the corresponding range. For example, high range keys have
corresponding high range key bits (136) in the high range bit
string (132) while low range keys have corresponding bits (138) in
the low range bit string (134). For example, state detector data
encoded by encode key set 1 is encoded in high range key 1 bit
(136B) and in low range key 1 bit (138B). Thus, two bits in the
signature (130) are used to represent the three possible
ranges.
[0034] Encode keys may be defined as a single numeric value and a
bit position. In particular, the high range encode key may be
defined by the high number in which all values above the high
number are in the high range. Conversely, the low range encode key
may be defined by the low number in which all values below the low
number are in the low range. For example, state detector data
values above the value of the high range key are in the high range
and therefore are encoded as a "1" in the high range key bit (136).
Similarly, state detector data values below the low range key are
in the low range and therefore are encoded as a "1" in the low
range key bit (138). State detector data values that are lower than
the high range key and higher than the low range key are in the
acceptable range and may be encoded as a "0" in the high range key
bit (136) and as a "0" in the low range key bit (138).
[0035] For the following example, consider the scenario in which
the high range is above 295, the low range is below 225, and the
normal range is between 225 and 295. In the example, a high range
key may define that state detector data having a value above 295 is
encoded as a "1" for the high range bit. Further, in the example, a
low range key may define that state detector data having a value
below 225 is encoded as a "1" for the low range bit. Thus, in the
example, a state detector data value of 312 is assigned a "1" for
the high range bit and a "0" for the low range bit.
[0036] As discussed above, FIG. 2 is only an example of one
possible format for the signature. Alternative variations for the
format of the signature may be used. Below is a discussion of some
of the different variations that may not be represented directly in
FIG. 2.
[0037] In a first variation, a different encoding than discussed
above may be used. Specifically, a value of "0" may be used to
represent when the state detector data value is in the range
specified by the bit. For example, rather than using a value of
"1", a value of "0" in the high range key bit may represent when
the state detector data value is above the high range key.
[0038] In another variation, although FIG. 2 shows only two bit
strings, additional bit strings may be used to represent additional
ranges. For example, consider the scenario in which the data is to
be encoded into a low range, a below normal range, a normal range,
an above normal range, and a high range. In the example, the five
different ranges may be represented by three or four bits depending
on the encoding. For example, using the encoding discussed above,
four bits may be used. Each of the four bits represents whether the
state detector data value is one of the four abnormal ranges.
Alternatively, three bits may be used to represent the five ranges.
In such an alternative, more than one of the three bits may be "1"
in the generated signature. For example, the following encoding may
be used for the state detector data value: "000" represents normal
range, "001" represents below normal range, "011" represents low
range, "100" represents above normal range, and "110" represents
high range.
[0039] In another variation, rather than identifying whether the
state detector data value is within a range of values, an encode
keys may be used to specify when the value is a member of a
discrete set of values. In such scenario, rather than having a high
range key bit and a low range key bit, the signature may have a
single bit that represents whether the value of the state detector
data is in the set. For example, consider the scenario in which the
discrete set of values is X1, X2, X3, X4, and X5. A value of "1"
may be used to represent when the value of the state detector data
is either X1, X2, X3, X4, or X5 while a value of "0" may be used to
represent when the value of the state detector data is not X1, X2,
X3, X4, or X5. Thus, in the example, X3 maps to "1" while X7 maps
to "0" as defined by the encode key set.
[0040] In another variation of FIG. 2, the number of encode keys in
the encode key set may not be uniform. Thus, the number of bits in
the high range bit string may be different from the number of bits
in the low range bit string. For example, consider the scenario in
which a first portion of the state detector data have four
corresponding encode keys (e.g., to represent a low range, a below
normal range, a normal range, an above normal range, and a high
range), a second portion has two corresponding encode keys (e.g.,
to represent a low range, a normal range, and a high range), and a
last portion have a single encode key (e.g., to represent when the
value of the state detector data is in the set represented by the
encode key). In the example scenario, the signature may have five
bit strings (e.g., a low range bit string, a below normal range bit
string, an above normal bit string, a high range bit string, and a
single set bit string). The low range bit string and the high range
bit string may have bits for both the first portion and the second
portion of the state detector data. The below normal bit string and
above normal bit string may have bits for only the second portion
of state detector data. The single set bit string may have bits for
the last portion of state detector data.
[0041] In another variation, virtually any configuration of bits in
the signature may be used. For example, although FIG. 2 shows
having a high range bit string and a low range bit string, bit
positions for encode keys in the same encode key set may be
adjacent. As an example, bits that encode temperature may be
adjacent rather than in separate bit strings.
[0042] Further, although FIG. 2 shows the bit strings as separated,
the bit strings may be concatenated to form the signature.
Specifically, bit b.sub.p in the high range bit string (132) may
immediately precede bit b.sub.0 in the low range bit string (134).
Thus, the signature may be the concatenation of the bit
strings.
[0043] Further, although FIG. 2 shows the signature as a bit
string, those skilled in the art will appreciate that the
signature, when presented to the user, may be the numeric value of
the bit string. Specifically, each bit string has a unique numeric
value for the data type. For example, the bit string "00000110" in
the unsigned byte data type represents the value of six.
[0044] Those skilled in the art will appreciate that the above is
only a few of the possible variations of the signature. Different
variations maybe used without departing from the scope of the
invention.
FIGS. 3A-3C:
[0045] FIGS. 3A-3B show example patterns in accordance with one or
more embodiments of the invention. A pattern associates the
occurrence of one or more signatures with a definition of how the
piece of equipment is functioning. As shown in FIG. 3A, a pattern
(140) may include a classified signature (142) and a frequency of
the classified signature (144) in accordance with one or more
embodiments of the invention.
[0046] A classified signature (142) is a pre-defined signature that
is previously associated with a pattern. Thus, the configuration of
encode key bits in the classified signature (142) is the same as
the configuration in a generated signature. In one or more
embodiments of the invention, the frequency of the classified
signature (144) defines the number of signatures matching the
classified signature (142) that must be generated within a
specified duration before the equipment is evaluated as functioning
as defined by the pattern.
[0047] For the following example, consider the scenario in which
the frequency of the classified signature is four of the classified
signatures in three minutes. In the example, the first time that a
signature is generated which matches the classified signature, the
signature analyzer may be undecided whether the equipment is
functioning as defined by the pattern or whether faulty data is
obtained. If three additional matching signatures are generated
within the three minutes, then the equipment may be evaluated to be
functioning as defined by the pattern. The pattern may or may not
require that the signatures are consecutively generated.
[0048] As shown in FIG. 3B, patterns (150) may be nested in
accordance with one or more embodiments of the invention.
Specifically, a pattern (150) may include one or more patterns. For
example, as shown in FIG. 3B, pattern A (150A) includes pattern B
(150B) and pattern C (150C). Pattern B (150B) and pattern C (150C)
may be any of the patterns represented in FIGS. 3A-3C.
[0049] Further, as shown in FIG. 3C, in addition to nested
patterns, a pattern (154A) may also include a sequence definition
(156). The sequence definition (156) defines an ordering between
the nested patterns (154B, 154C). Specifically, the sequence
definition (156) defines whether pattern B (154B) precedes or
succeeds pattern C (154C) before a state of the equipment is
detected. Additionally, the sequence definition may describe the
number of times each of the nested patterns is generated.
[0050] Using the pattern definitions described in FIGS. 3A-3C, an
example pattern is: "<signature A>, <signature B>,
<frequency of signature B=2>, <sequence definition:
signature A precedes signature B><signature C>". While the
example shows one technique for defining a pattern, many different
techniques may be used. For example, the example pattern definition
may be stored as previously described or as "<signature A>,
<signature B>, <signature B>, <signature C> and
<signature C> <signature A>, <signature B>,
<signature B>".
FIGS. 4-7:
[0051] FIGS. 4-7 show flowcharts in accordance with one or more
embodiments of the invention. While the various steps in this
flowchart are presented and described sequentially, one of ordinary
skill will appreciate that some or all of the steps may be executed
in different orders, may be combined or omitted, and some or all of
the steps may be executed in parallel.
[0052] FIG. 4 shows a flowchart for generating encode keys in
accordance with one or more embodiments of the invention. In one or
more embodiments of the invention, patterns are defined separately
for each piece of equipment. Each pattern is associated with a
definition of how the piece of equipment is functioning. In step
201, the equipment is identified. A set of state detectors related
to the evaluation of the equipment is identified in step 203. In
one or more embodiments of the invention, the set of identified
state detectors include all state detectors required to monitor and
evaluate the equipment.
[0053] From the set of state detectors, the type of state detector
data to encode is identified in Step 205. Specifically, the type of
state detector data that is identified may be unprocessed state
detector data obtained from a specific state detector.
Alternatively, the type of state detector data that is identified
may be processed state detector data that is created by performing
a specific set of steps on unprocessed state detector data obtained
from one or more state detectors. For example, the type of state
detector data that is identified may be unprocessed data such as
temperature, or processed data, such as the pressure drop between
inlet and outlet pressure.
[0054] For the identified type of state detector data, the ranges
of the state detector data values are identified in Step 207. In
one or more embodiments of the invention, a determination is made
as to the number of ranges to define for the state detector data.
For each of the ranges, the boundaries of the range are identified.
In one or more embodiments of the invention, the boundaries are
identified from historical data, experience with the same or
similar equipment, and/or specifications from the equipment
manufacturer.
[0055] In step 209, encode keys are created based on the ranges.
Specifically, the boundaries of each of the ranges are used to
define the encode keys. Thus, a mapping is created between the
boundaries of the ranges and values for the encode key bit. The
encode keys are stored in Step 211. In one or more embodiments of
the invention, an ordering of the encode key bits in the signature
for the equipment is defined. Specifically, each encode key is
assigned a position in the signature.
[0056] In step 213, a determination is made whether to create
additional encode key sets. If a determination is made to create
additional encode key sets, then the method repeats with Step
207.
[0057] Once encode keys exist, the configuration of the bits in the
signature is defined. Thus, one or more patterns may be defined
(not shown). In one or more embodiments of the invention, a pattern
is defined based on the type of evaluation to perform for the
equipment.
[0058] For the following example, consider the scenario in which
the evaluation of the equipment is to detect failure or the
potential for failure. In such an example, the different types of
failure modes of the equipment are identified. For each of the
different types of failure modes, the symptoms of the failure modes
are identified. In particular, a determination is made as to the
state detector data values from each state detector that typically
exists prior to the failure associated with the failure mode. Based
on the state detector data values and the encode keys, a classified
signature is defined. The classified signature may be used to
define the pattern. Specifically, a determination may be made as to
the number of times in which signatures matching the classified
signature is to be generated before the failure is detected. The
number of times and the classified signature may be stored in the
data repository as a pattern. If the type of failure mode requires
a change in the state detector data values over time, then multiple
classified signatures may be defined. In such a scenario, a pattern
may be created by requiring that the multiple classified signatures
occur in succession.
[0059] FIG. 5 shows a flowchart for generating a signature in
accordance with one or more embodiments of the invention. As shown
in FIG. 5, signature creation is initiated in Step 221.
Specifically, an empty signature is defined.
[0060] In step 223, unprocessed state detector data is obtained
from the state detectors. For example, sensors on the equipment may
gather the state detector data from the equipment and store the
state detector data in a data repository. The unprocessed state
detector data may be processed to create processed state detector
data. For example, the processing may include calculating changes
in the operational state of the equipment using the unprocessed
state detector data, calculating the performance of the equipment,
and performing other such calculations. The processed state
detector data may also be stored in the data repository.
[0061] In step 225, an encode key set is obtained. The unit of
state detector data corresponding to the obtained code key set is
identified in step 227. Specifically, an identification is made as
to which state detector data is encoded by the encode key set. The
values of the identified state detector data may be obtained from
the data repository. Using the encode key set, the state detector
data is encoded to obtain encoded data in step 229. The encoded
data is added to the location in the signature specified by the
encode key set (Step 231). In step 233, a determination is made
whether another encode key set exists. If another encode key set
exists, then the method may repeat with step 225. If no other
encode key set exists, then the signature generation is
complete.
[0062] FIG. 6 shows a flowchart for determining whether generated
signatures match a pattern in accordance with one or more
embodiments of the invention. The generated signature is compared
with classified signatures in the repository (Step 241).
Specifically, the generated signatures are compared with each of
the classified signatures in each pattern in the repository. Those
skilled in the art will appreciate that multiple different methods
for comparing signatures may be used without departing from the
scope of the invention. For example, the comparison may be
performed by performing a bitwise comparison. In another example, a
determination may be made whether the number represented by the
generated signature matches the number represented by a classified
signature. If the number matches, then the signature matches. In
step 243, a determination is made whether a match is found.
[0063] If a match is not found, then the generated signature is
stored in accordance with one or more embodiments of the invention
(Step 245). Storing the generated signature provides a historical
record of the generated signatures. Using the historical record,
new patterns may be learned in accordance with one or more
embodiments of the invention.
[0064] If a match is found, then the pattern(s) having the
classified signature that matches the generated signature
identified in Step 247. In one or more embodiments of the
invention, more than one pattern may be identified. Specifically,
the same classified signature may be in multiple different patterns
of signatures.
[0065] In one or more embodiments of the invention, a determination
is made whether to trigger an event based on a pattern in step 249.
An event is triggered when one or more generated signatures match a
pattern.
[0066] In step 251, an event is triggered based on the
determination. Specifically, the action corresponding to the
matched pattern is identified. The steps of the action are
performed. For example, an alert may be issued via email, text, or
phone, or a message may be displayed that defines the state of the
equipment. Further, rather than or in addition to triggering an
alert, the event engine may automatically adjust the equipment
according to the action. For example, the event engine may shut
down the equipment, adjust flow of the equipment, adjust operating
parameters of the equipment, or perform other actions.
[0067] Regardless of whether a determination is made to trigger an
event, the newly identified match is stored. Specifically, the
newly generated signature may be stored with identified matches.
Further, the newly generated signature may be stored for learning
additional patterns.
[0068] FIG. 7 shows a flowchart of a method for learning new
patterns for failure detection in accordance with one or more
embodiments of the invention. In step 261, a failure of the
equipment is detected. In one or more embodiments of the invention,
the failure of the equipment was not previously detected using the
patterns. For example, an operator of the equipment may determine
that the equipment is no longer functioning properly.
[0069] Stored signatures that were generated for the equipment
prior to the failure are obtained in step 263. At this stage, the
data repository is accessed to identify all signatures generated
prior to the failure.
[0070] In step 265, the generated signatures are analyzed to
identify a new pattern. Different methods may be used to analyze
the generated signatures. For example, the analysis may include
determining the symptoms of the failure that existed prior to the
failure. Based on the symptoms, the state detector data that may
identify the existence symptoms are identified. The encode key bits
corresponding to the identified state detector data are identified.
The identified encode key bits in the generated signatures are used
to define a new pattern. In step 267, the new pattern is stored in
the data repository.
FIGS. 8A-8B:
[0071] FIGS. 8A-8B show an example in accordance with one or more
embodiments of the invention. The following is for exemplary
purposes only and not intended to limit the scope of the invention.
In the following hypothetical example, consider the scenario in
which Equipment X is being monitored to prevent failure. Equipment
X has four state detectors (i.e., sd1, sd2, sd3, sd4) gathering
unprocessed state detector data from equipment X. Those skilled in
the art will appreciate that, in actuality, many more state
detectors may be gathering state detector data from equipment
X.
[0072] FIG. 8A shows encode key sets for state detector data from
Equipment X (300) in accordance with one or more embodiments of the
invention. As shown in the example FIG. 8A, encode key set 1 (302)
encodes unprocessed state detector data from state detector sd1.
The low range encode key is 5.759 and the high range encode key is
5.963 in encode key set 1 (302). Encode key set 2 (304) encodes
unprocessed state detector data from state detector sd2. The low
range encode key is 35 and the high range encode key is 96 in
encode key set 2 (304).
[0073] Encode key set 3 (306) encodes processed state detector
data. Specifically, to obtain the processed state detector data
value for encode key set 3 (306), the state detector data value
from state detector sd2 is subtracted from the state detector data
value from state detector sd3. The low range encode key for the
processed state detector data is -352 and the high range encode key
is 48 in encode key set 3 (304).
[0074] Encode key set 4 (308) encodes unprocessed state detector
data from state detector sd4. The low range encode key is 96.3 and
the high range encode key is 165.8 in encode key set 4 (308).
[0075] In the hypothetical example, the bits of each signature are
in the following order: low range key bit for encode key 1, low
range key bit for encode key 2, low range key bit for encode key 3,
low range key bit for encode key 4, high range key bit for encode
key 1, high range key bit for encode key 2, high range key bit for
encode key 3, high range key bit for encode key 4.
[0076] Continuing with the hypothetical example, FIG. 8B shows
example patterns for detecting a failure in accordance with one or
more embodiments of the invention. In the example, the patterns may
be used to detect three different types of failures. Specifically,
pattern 1 (310) associates classified signature 00111000 with
failure type 1. The operator is emailed when the classified
signature in pattern 1 (310) is generated. Pattern 2 (312)
associates classified signatures in a pattern of 00000001,
00100001, 10100001 with failure type 2. Equipment X is stopped when
pattern 2 (312) is matched. Pattern 3 (314) associates classified
signature 00000010 occurring eight times in twelve minutes with
failure type 3. A valve is replaced when pattern 3 (314) is
detected.
[0077] Continuing with the example, unprocessed state detector data
is collected from the equipment. For example, at time t.sub.0, 5.83
is obtained from sd1, 40 is obtained from sd2, -258 is obtained
from sd3, and 179 is obtained from sd4. The state detector data for
time t.sub.0 is encoded using the encode keys in FIG. 8A.
Specifically, 5.83 is in the normal range for encode key set 1.
Therefore, 5.83 is encoded as 0 for the high range key bit and 0
for the low range key bit. 40 is also in the normal range for
encode key set 2 and therefore is similarly encoded. Similarly,
-258-40 equals -298 for encode key set 3 and is also in the normal
range. However, 179 from sd4 is above normal and is therefore
encoded as a 0 for the low range bit and a 1 for the high range
bit. Accordingly, the signature generate for time t.sub.0 is
00000001.
[0078] The generated signature 00000001 is compared with patterns
in FIG. 8B. At this stage, the generated signature matches only one
classified signature in pattern 2 (312). Because the pattern is not
completely matched, no failure is detected.
[0079] At time t.sub.1, 5.92 is obtained from sd1, 41 is obtained
from sd2, -318 is obtained from sd3, and 190 is obtained from sd4.
Similar to encoding the state detector data for time t.sub.0, the
state detector data for time t.sub.1 is encoded using the encode
keys in FIG. 8A. Accordingly, the resulting signature is 00100001.
The generated signature 00100001 is compared with patterns in FIG.
8B. At this stage, the generated signatures from times t.sub.0 and
t.sub.1 matches two of the classified signature in pattern 2 (312).
Because the pattern is not completely matched, no failure is
detected.
[0080] At time t.sub.2, 5.97 is obtained from sd1, 38 is obtained
from sd2, -317 is obtained from sd3, and 223 is obtained from sd4.
Similar to encoding the state detector data for times t.sub.0 and
t.sub.1, the state detector data for time t.sub.2 is encoded using
the encode keys in FIG. 8A. Accordingly, the resulting signature is
10100001. The generated signature 10100001 is compared with
patterns in FIG. 8B. At this stage, the generated signatures from
times t.sub.0, t.sub.1, and t.sub.2 matches the pattern 2 (312).
Because the pattern is matched, failure 2 is detected and equipment
X is immediately stopped.
[0081] Those skilled in the art will appreciate that the above is
for explanatory purposes only. At any given time multiple pieces of
equipment may be simultaneously monitored by state detectors. Each
piece of equipment may have many different types of failures that
may occur. The signatures may simplify the amount of state detector
data to consider when determining whether a failure exists.
FIG. 9:
[0082] Embodiments of the invention may be implemented on virtually
any type of computer regardless of the platform being used. For
example, as shown in FIG. 9, a computer system (400) includes one
or more processor(s) (402), associated memory (404) (e.g., random
access memory (RAM), cache memory, flash memory, etc.), a storage
device (406) (e.g., a hard disk, an optical drive such as a compact
disk drive or digital video disk (DVD) drive, a flash memory stick,
etc.), and numerous other elements and functionalities typical of
today's computers (not shown). The computer (400) may also include
input means, such as a keyboard (408), a mouse (410), or a
microphone (not shown). Further, the computer (400) may include
output means, such as a monitor (412) (e.g., a liquid crystal
display (LCD), a plasma display, or cathode ray tube (CRT)
monitor). The computer system (400) may be connected to a network
(414) (e.g., a local area network (LAN), a wide area network (WAN)
such as the Internet, or any other similar type of network) via a
network interface connection (not shown). Those skilled in the art
will appreciate that many different types of computer systems
exist, and the aforementioned input and output means may take other
forms. Generally speaking, the computer system (400) includes at
least the minimal processing, input, and/or output means necessary
to practice embodiments of the invention.
[0083] Further, those skilled in the art will appreciate that one
or more elements of the aforementioned computer system (400) may be
located at a remote location and connected to the other elements
over a network. Further, embodiments of the invention may be
implemented on a distributed system having a plurality of nodes,
where each portion of the invention (e.g., data repository,
signature generator, signature analyzer, etc.) may be located on a
different node within the distributed system. In one embodiment of
the invention, the node corresponds to a computer system.
Alternatively, the node may correspond to a processor with
associated physical memory. The node may alternatively correspond
to a processor with shared memory and/or resources. Further,
software instructions to perform embodiments of the invention may
be stored on a computer readable medium such as a compact disc
(CD), a diskette, a tape, a file, or any other computer readable
storage device.
ILLUSTRATIVE EMBODIMENTS
[0084] In one embodiment, there is disclosed a system comprising at
least one piece of equipment; a plurality of sensors adapted to
measure one or more operating parameters of the equipment; and a
signature generator adapted to encode a plurality of data streams
from the sensors into an operating signature for the equipment. In
some embodiments, the system also includes a signature repository
containing a number of signatures that correspond to known
operating conditions of the equipment. In some embodiments, the
system also includes an action repository containing a number of
actions to be taken which correspond to the signatures in the
signature repository. In some embodiments, the system also includes
a signature analyzer adapted to compare a signature from the
signature generator with a known signature from the signature
repository. In some embodiments, the system also includes an event
engine adapted to take a predetermined action when a signature from
the signature generator matches a known signature from the
signature repository. In some embodiments, the signature generator
produces a signature comprising at least two of a high, normal, and
low range bit string. In some embodiments, the signature generator
converts the bit string to a number.
[0085] In one embodiment, there is disclosed a method comprising
identifying at least one piece of equipment to be monitored;
installing a plurality of sensors to measure operating data of the
equipment; establishing an operating range for each of the sensors;
and creating an encoding key for each of the ranges. In some
embodiments, the method also includes converting a plurality of the
encoding keys into an operating signature. In some embodiments, the
method also includes storing a plurality of known signatures in a
database, the signatures corresponding to known operating
conditions of the equipment. In some embodiments, the method also
includes storing a plurality of actions to take in a database, the
actions corresponding to the known signatures. In some embodiments,
the method also includes comparing the operating signature with
known signatures in the database. In some embodiments, the method
also includes taking a predetermined action when the operating
signature matches a known signatures in the database. In some
embodiments, the method also includes storing a new signature in a
database, the signature corresponding to an observed or measured
operating condition of the equipment. In some embodiments, the
method also includes storing a new action in a database, the action
corresponding to a new signature, the new action designed to
correct observed or measured operating conditions of the
equipment.
[0086] While the invention has been described with respect to a
limited number of embodiments, those skilled in the art, having
benefit of this disclosure, will appreciate that other embodiments
can be devised which do not depart from the scope of the invention
as disclosed herein. Accordingly, the scope of the invention should
be limited only by the attached claims.
* * * * *